Ford Aerostar overheating problems

Filed Jul 22, 2005 · Electrical, Fuel system · WA · fire

My 1997 ford aero star van produced a puff of smoke from the steering column near the ignition switch. I took it to my mechanic whom checked the recall notices and found one resulting in an electrical overload short circuit and overheating in the steering column electrical components. When the key was turned off it subsides. Since this occurrence the instrument panel has not worked and blew all fuses, the fuel pump does not turn on with the key after multiple attempts it engages some times. The ford dealer did the recall work but did not fix or examine the steering column or the components that burned or over heated as a result of the overload. [xxx] updated 07/19/2012 *js information redacted pursuant to the freedom of information act (foia), 5 u.s.c. 552(b)(6)

Filed Jan 15, 2004 · Brakes, Fuel system · CA

Brakes overheat on a curvey road

Filed Nov 13, 2002 · Lights · ND

While driving at highway speeds at night, headlight switch (f49z-11654-a), with autolamp option, failed and headlights started flashing off and on then going out completely. This has occurred three times, 9/98 at 93,000 miles (switch replaced), 8/01 at 145,000 miles (new switch and block installed w/old wiring) and 10/02 at 160,000 miles (new switch and block w/new wiring installed). Vehicle normally driven with headlights on for safety so useage time on switch is extensive. Each time lights went out, the headlight switch contacts, terminals and wire terminal connectors had overheated and discolored. The overheating melted and distorted the plastic switch case and terminal block (d3tz-11a648-a), allowing or forcing terminals to distort or move. Both of the battery power to main light switch terminals, a & b and the main light switch to dimmer switch terminal, were the only ones overheated. Dt

Filed Apr 11, 2002 · Electrical, Fuel system · FL

An electrical short in fuel pump. Vehicle was experiencing a loss of power and fuel gauge becomes erratic. Dealer contacted. *ak all the gauges quit working and the engine stalls while driving due to main dash wiring harness overheated and burnt.

Filed Nov 19, 2001 · Brakes, Transmission · CA · fire

Ford recommends incorrect adjustment of rear brakes, which causes overheating of drums and eventual failure of axle seals, axle bearings, and tire on the rim attached to the brake drum. Ford stipulates that brake shoes are to be touching drum when brakes are adjusted. This results in frictional heat build-up, and is likely to be a contributor to tire failures reported with the ford explorer. The ford explorer, aerostar, and ranger all share power train and drive train components. This practice has cost me $000s on my 4 ford aerostars (1989, 1992, 1994, and 1997 model years)

Filed Jul 21, 2001 · Lights · IN

The original headlight switch overheated & the brake,tail,dash & head lts go off, switch 1/2 in will work. Replacement after approx 1 yr is doing same.

Filed Jul 1, 2001 · Transmission · AL

While driving in the smoky mountains in nc the transmission overheated and poured out transmission fluid. The van began to smoke and I pulled over in a dangerous place. I decided to turn around (also in dangerous place) I went back to cherokee, nc and a mechanic said this was a common problem for areostars. He said many people get ripped off by untrustworthy mechanics. While traveling over the mountains we saw three other areostars with the same problem. Two were being towed by wreckers. Areostar owners need to be notified of this problem. That the transmission will overheat under a load and transmission fluid will be lost. We were very upset by this and our vacation was ruined. But because we found a good mechanic we were not ripped off. I cannot say the same about the other vans that we saw being towed from the mountain and we were only there for a couple of hours and saw three others in trouble.

Filed May 23, 2001 · Engine · OH

Vehicle experiencing problem with loss of coolant and overheating while driving. Independent mechanic informed of a head gasket failure. Vehicle was not covered under manufacturer's extended warranty. Feel free to provide any further details on this matter.

Filed Apr 10, 2001 · Fuel system · WA

Fuel pump usually does not come on until repeatedly turning ignition on and off, vehicle died twice while driving and would not restart until fuel pump came on, smells like vehicle overheating when it should not be, same problems as described in ford press release regarding recall 99 s 02, taken to (different) dealership for repair, denies problem is recall related

Filed Mar 27, 2001 · Engine · FL

Vehicle overheated/ stalled due to blowen headgaskets. Dealer was inspecting vehicle.